Mattresses with multiple customizable and replaceable levels and sections and methods thereof

ABSTRACT

A mattress including a customizable and replaceable mattress core, two or more customizable and replaceable foam sections, a customizable and replaceable panel and at least one connection device. The two or more customizable and replaceable foam sections are positioned on a surface of the customizable and replaceable mattress core. The customizable and replaceable panel is positioned over the two or more customizable and replaceable foam sections. The connection device has detachably mating connector portions. One of the detachably mating connector portions is secured adjacent at least a portion of an outer periphery of the customizable and replaceable panel. Another of the detachably mating connector portions is secured adjacent at least a portion of another outer periphery of the surface of the customizable and replaceable mattress core. The detachably mating connector portions of the connection device detachably secure the customizable and replaceable panel to the customizable and replaceable mattress core and retain the position of the two or more customizable and replaceable foam sections.

This is a continuation application of U.S. patent application Ser. No. 15/337,826 filed Oct. 28, 2016, which claims the benefit of U.S. Provisional Patent Application Ser. No. 62/249,037, filed Oct. 30, 2015, and U.S. Provisional Patent Application Ser. No. 62/274,887, filed Jan. 5, 2016, which are hereby incorporated by reference in their entirety.

FIELD

This technology generally relates to mattresses and, more particularly, to mattresses with multiple customizable and replaceable levels and sections and methods thereof.

BACKGROUND

Today, most mattresses that are sold are innerspring mattresses, although there is increasing interest in and demand for other types of mattresses, such as foam mattresses made from polyurethane foam or latex. Customers contain to seek mattresses that will provide them with a better night's sleep.

Unfortunately, despite ongoing research and development efforts, mattresses often still fall short of customers' expectations for sleep comfort and support as well as durability. Additionally, even though there are greater numbers and types of mattresses available, they still can not be adjusted or customized sufficiently for the changing needs of customers or for the different types and/or numbers of customers that might be using the mattress to sleep. Further, when at least a portion of a mattress begins to wear out, existing mattresses still require replacement of the entire mattress which is expensive.

SUMMARY

A mattress including a customizable and replaceable mattress core, two or more customizable and replaceable foam sections, a customizable and replaceable panel and at least one connection device. The two or more customizable and replaceable foam sections are positioned on a surface of the customizable and replaceable mattress core. The customizable and replaceable panel is positioned over the two or more customizable and replaceable foam sections. The connection device has detachably mating connector portions. One of the detachably mating connector portions is secured adjacent at least a portion of an outer periphery of the customizable and replaceable panel. Another of the detachably mating connector portions is secured adjacent at least a portion of another outer periphery of the surface of the customizable and replaceable mattress core. The detachably mating connector portions of the connection device detachably secure the customizable and replaceable panel to the customizable and replaceable mattress core and retain the position of the two or more customizable and replaceable foam sections.

A method for making a mattress includes selecting one of a plurality of different customizable and replaceable mattress cores. Two or more customizable and replaceable foam sections are positioned on a surface of the selected one of the plurality of customizable and replaceable mattress cores. A customizable and replaceable panel is positioned over the two or more customizable and replaceable foam sections. Detachably mating connector portions of at least one connection device are detachably mated. One of the detachably mating connector portions is secured adjacent at least a portion of an outer periphery of the customizable and replaceable panel. Another of the detachably mating connector portions is secured adjacent at least a portion of another outer periphery of the surface of the selected one of the plurality of different customizable and replaceable mattress cores. The detachably mating connector portions of the connection device detachably secure the customizable and replaceable panel to the selected one of the plurality of different customizable and replaceable mattress cores and retain the position of the two or more customizable and replaceable foam sections.

This technology provides a number of advantages including providing a mattress with customizable and replaceable levels and sections. With this technology, the mattress can easily adjust comfort levels and/or styles over different levels and sections of the mattress to provide a uniquely customized mattress. Additionally, with this technology complete replacement of a mattress is no longer required because customers can less expensively replace different levels and/or sections as needed or desired.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example of a mattress with multiple customizable and replaceable levels and sections;

FIG. 2 is an enlarged view of an example of a zipper connector for the example of mattresses with multiple customizable and replaceable levels and sections shown in FIG. 1;

FIG. 3 is a partial, side cross-sectional view of examples of customizable and replaceable levels of a mattress;

FIGS. 4A-4C are diagrams of examples of different types of customizable and replaceable mattress cores; and

FIGS. 5A-5C are top views of different examples of configurations of customizable and replaceable foam sections.

DETAILED DESCRIPTION

An example of a mattress 10 with customizable and replaceable levels and sections is illustrated FIGS. 1-3. In this example, the mattress 10 has three levels including a customizable and replaceable mattress core 12(1), customizable and replaceable foam sections 14(1)-14(2), and a customizable and replaceable fabric panel 16, although the mattress can have other types and/or numbers of levels and/or sections and may include other types and/or numbers of other components and/or other elements in other arrangements, such as the zipper connector 18. This technology provides a number of advantages including providing a mattress that allows mixing and matching of customizable and replaceable mattress cores, customizable and replaceable foam sections, and/or customizable and replaceable fabric panels to adjust comfort levels and/or styles as well as to facilitate easy and less expensive refurbishment rather than complete replacement.

Referring more specifically to FIGS. 1-4C, the mattress 10 includes the customizable and replaceable mattress core 12(1) that forms the base of the mattress 10, although the mattress could have other types and/or numbers of other bases or other foundations. In this particular example as shown in FIG. 1, the customizable and replaceable mattress core 12(1) comprises three layers 13(1)-13(3) and each layer may comprise the same or different types of material as selected. Additionally, the customizable and replaceable mattress core 12(1) could be a unitary construction comprising a foam mattress core 12(1) as shown in FIG. 4A, as an open coil mattress core 12(2) shown in FIG. 4B or a pocket coil mattress core 12(3) as shown in FIG. 4C by way of example only, although other types of mattress cores can be used, such as a mattress core with a water filled section. Further, a customizable and replaceable mattress core 12(4) may comprise three different sections 15(1)-15(3) where at least two of the sections are different types of mattress cores, such as foam, open coil, and/or pocket coil by way of example only. These multiple mattress core sections which form the customizable and replaceable mattress core may have different symmetric or asymmetric configurations, such as those illustrated and described later herein for the customizable and replaceable foam sections with reference to FIGS. 5A-5C by way of example. Accordingly, with this technology a particular type of mattress core with certain layer or layers and/or section or sections of different types of materials can be selected and/or later replaced as needed. By way of example only, on one side of a mattress a sleeper may prefer a memory foam mattress core section for a certain type of support while on the other side of the mattress the other sleeper may prefer an open coil mattress core section which provides more air flow.

The mattress 10 may also include two customizable and replaceable foam sections 14(1)-14(2) that are placed on and substantially covering the mattress core 12, although other types and/or numbers of customizable and replaceable foam sections in other sizes and/or arrangements could be used, such as just one section or three or more sections. In this example, the two customizable and replaceable foam sections 14(1)-14(2) are placed adjacent or parallel to each other along a length of the mattress core 12 as shown in FIGS. 1 and 4A, although the two customizable and replaceable foam sections can be placed using other arrangements. For example, the mattress 10 may also include three customizable and replaceable foam sections 14(3)-14(5) arranged in a parallel zone configuration as shown in FIG. 5B to provide customized foam sections for each sleeper and also a transition zone comprising customizable and replaceable foam section 14(4) between customizable and replaceable foam sections 14(3) and 14(5) to smooth the transition between the different customizable and replaceable foam sections 14(3) and 14(5). In another example, the mattress 10 may also include three customizable and replaceable foam sections 14(6)-14(8) arranged in an asymmetric zone configuration as shown in FIG. 5C to again provide customized foam sections for each sleeper and also provide a transition zone with customizable and replaceable foam section 14(7) to smooth the transition between the different customizable and replaceable foam sections 14(6) and 14(8) adjacent the upper body portions of the sleepers.

Each of the customizable and replaceable foam sections 14(1)-14(8) may be selected to have a different amount of firmness so a foam comfort level, such as a soft, medium, or firm comfort levels by way of example only, of the mattress 10 can be adjusted to the particular sleepers, such as the his side and her side having different foam comfort levels as illustrated in the example in FIG. 1. Each of the customizable and replaceable foam sections 14(1)-14(8) may also have different foam densities. Foam density is a specific measurement of how much weight in pounds foam can handle per cubic foot and may impact quality and durability of the foam sections 14(1)-14(8) and thus how long before replacement. As a result, foam sections 14(1)-14(8) with a particular foam density could be selected for example to extend the time before replacement might be needed or in another example to minimize cost by selecting a foam density with an acceptable anticipate life span at a lower cost. Additionally, each of the customizable and replaceable foam sections 14(1)-14(8), may have one or more other features, such as a ribbed or otherwise contoured surface to adjust the comfort or feel by way of example only. Further, other numbers of customizable and replaceable foam sections in other configurations may be used and again each of the customizable and replaceable foam sections can be easily replaced as desired and/or needed because of wear or other use.

In this particular example, the customizable and replaceable foam sections 14(1)-14(2) each have three different types of foam layers 17(1)-17(4) as shown in FIG. 3 to insure extended support and comfort, although each could have other types and/or numbers of layers. Additionally, in this particular example, the bottom layer 17(4) comprises an extra hard 100% breathable foam layer that provides support with ventilation, the middle layers 17(2) and 17(3) comprises hard foam layers that provides a touch of softness while maintaining the body support, and the top layer 17(1) comprises a soft foam layer for a premium luxury welcoming feeling, although other types and/or numbers of layers can be used for each of the customizable and replaceable sections.

While in this particular example there are no connectors to hold the different combinations and configurations of the customizable and replaceable foam sections 14(1)-14(8) together as shown in the examples in FIGS. 5A-5C apart from the customizable and replaceable fabric panel 16 with the zipper connector 18, one or more other connectors may be used. For example, the different combinations and configurations of the customizable and replaceable foam sections 14(1)-14(8) may be held together by hook and loop fasteners, glue, elastic bands, and/or rivet buttons by way of example only, although other types and/or numbers of connectors may be used.

The mattress 10 may also include the customizable and replaceable panel 16 made of a fabric or other material or materials, such as cotton, synthetic fibre, cashmere, coir, or polyester by way of example only, although other types and/or numbers of panels comprising other types and/or numbers of materials may be used. In this example, the customizable and replaceable panel 16 comprises a sheet which is made of two layers of one (1) cm thick thirteen (13) density foam and is washable, although other types and/or numbers of panels made of other types, layers and/or numbers of materials could be used. With this technology, the customizable and replaceable panel 16 can be changed as needed or desired to adjust the comfort level and also to permit less expensive partial replacement of the mattress 10.

The zipper connector 18 is used to detachable secure an outer periphery or edge of the customizable and replaceable panel 16 to an outer periphery or edge of the customizable and replaceable mattress core 12(1), although other types and/or numbers of detachable connectors which may be in other locations could be used, such as buttons or hook and loop fasteners by way of example only. Additionally, although a zipper connector 18 is shown other manners for securing the one or more customizable and replaceable foam sections, such as the different combinations and configurations of the customizable and replaceable foam sections 14(1)-14(8), to the mattress core 12(1) may be used. Further, in this example the zipper connector 18 may comprise detachably mating zipper connector portions 19(1) and 19(2) which are each respectively attached to an outer edge or periphery of the customizable and replaceable panel 16 and the customizable and replaceable mattress core 12(1). The zipper connector 18 with the detachably mating zipper connector portions 19(1) and 19(2) may be used to detachably secure the fabric panel 16 to the mattress core 12(1) to hold the one or more customizable and replaceable foam sections, such as the different combinations and configurations of the customizable and replaceable foam sections 14(1)-14(8), in place, although other types and/or numbers of securing mechanisms could be used, such as hook and loop fasteners, glue, or elastic straps by way of example only.

An example of a method for using the mattress 10 will now be illustrated and described with reference to FIGS. 1-5C. In this example, one of a plurality of mattress cores 12(1)-12(3) may be selected, although other types and/or numbers of mattress cores could be used. Additionally, the mattress core that is selected could have different numbers and/or types of layers as shown in the example in FIG. 1 and/or may comprise two or more different mattress core sections 15(1)-15(3) as shown in FIG. 3 to provide numerous options for customizing the mattress core for the mattress 10 for each particular sleeper.

Next, the one or more customizable and replaceable foam sections, such as the different combinations and configurations of the customizable and replaceable foam sections 14(1)-14(8), may be placed on a surface of the selected one of the customizable and replaceable mattress core 12(1). Again these different numbers and/or combinations of foam sections can be selected to customize the sleeping surface for each sleeper for the mattress 10. As described in greater detail earlier, each of the customizable and replaceable foam sections 14(1)-14(8) may have different types and/or numbers of layers which provide different levels of firmness, feel, and/or comfort and may be selected based on those or other types and/or numbers of factors. In this example, no connectors are used to hold the selected one of the combinations and configurations of the customizable and replaceable foam sections 14(1)-14(8) in place, although one or more connectors could be used.

Next, in this example the zipper connector 18 with the detachably mating zipper connector portions 19(1) and 19(2) can be used to secure the selected one of the combinations and configurations of the customizable and replaceable foam sections 14(1)-14(8) in place. In particular, the zipper connector portions 19(1) and 19(2) which are each respectively attached to an outer edge or periphery of the customizable and replaceable panel 16 and the customizable and replaceable mattress core 12(1) can be detachably mated together, although again other types and/or numbers of connectors in other locations could be used.

Accordingly, this technology provides a number of advantages including providing a mattress that allows mixing and matching of customizable and replaceable mattress cores, customizable and replaceable foam sections, and/or customizable and replaceable fabric panels to adjust comfort levels and/or styles as well as to facilitate easy and less expensive refurbishment rather than complete replacement. With this technology, a mattress can be provided with a selected level of softness, comfort, and support for each sleeper. Further, each of the levels and regions of the mattress are customizable and replaceable extending the overall life of the mattress and providing a more economical mattress solution for customers.

Having thus described the basic concept of the technology, it will be rather apparent to those skilled in the art that the foregoing detailed disclosure is intended to be presented by way of example only, and is not limiting. Various alterations, improvements, and modifications will occur and are intended to those skilled in the art, though not expressly stated herein. These alterations, improvements, and modifications are intended to be suggested hereby, and are within the spirit and scope of the technology. Additionally, the recited order of processing elements or sequences, or the use of numbers, letters, or other designations therefore, is not intended to limit the claimed processes to any order except as may be specified in the claims. Accordingly, the technology is limited only by the following claims and equivalents thereto. 

What is claimed is:
 1. A mattress comprising: three or more different types of customizable and replaceable mattress core sections arranged in an asymmetrical configuration with one of the customizable and replaceable mattress core sections comprising a transition region that is positioned between and smaller than the other customizable and replaceable mattress core sections and wherein a longer side of each of the customizable and replaceable mattress core sections extends along a length of the mattress; three or more customizable and replaceable foam sections positioned on a surface of the three or more different types of customizable and replaceable mattress core sections; a customizable and replaceable panel positioned over the three or more customizable and replaceable foam sections; and at least one connection device comprising detachably mating connector portions, one of the detachably mating connector portions secured adjacent at least a portion of an outer periphery of the customizable and replaceable panel and another of the detachably mating connector portions secured adjacent at least a portion of another outer periphery of the surface of the three or more customizable and replaceable foam sections, the detachably mating connector portions of the connection device detachably securing the customizable and replaceable panel to the customizable and replaceable mattress core and retaining the position of the two or more customizable and replaceable foam sections.
 2. The mattress as set forth in claim 1 wherein at least two of the three or more customizable and replaceable foam sections have a different foam comfort level.
 3. The mattress as set forth in claim 1 wherein the three or more customizable and replaceable foam sections are positioned in an asymmetric zone configuration, at least two of the foam sections have a different shape, and at least two of the foam sections have a different foam comfort level.
 4. The mattress as set forth in claim 1 wherein each of the three or more customizable and replaceable foam sections comprises a foam memory mattress core, an open coil mattress core, or a pocket coil.
 5. The mattress as set forth in claim 1 wherein at least two of the three or more customizable and replaceable mattress sections are different types of mattress cores.
 6. The mattress as set forth in claim 1 wherein the customizable and replaceable panel comprises a padded fabric panel.
 7. The mattress as set forth in claim 1 wherein the connection device comprises at least one zipper connector.
 8. A method for making a mattress, the method comprising: providing three or more different types of customizable and replaceable mattress core sections arranged in an asymmetrical configuration with one of the customizable and replaceable mattress core sections comprising a transition region that is positioned between and smaller than the other customizable and replaceable mattress core sections and wherein a longer side of each of the customizable and replaceable mattress core sections extends along a length of the mattress; positioning three or more customizable and replaceable foam sections on a surface of the three or more different types of customizable and replaceable mattress core sections; positioning a customizable and replaceable panel over the three or more customizable and replaceable foam sections; and providing at least one connection device comprising detachably mating connector portions, one of the detachably mating connector portions secured adjacent at least a portion of an outer periphery of the customizable and replaceable panel and another of the detachably mating connector portions secured adjacent at least a portion of another outer periphery of the surface of the three or more customizable and replaceable foam sections, the detachably mating connector portions of the connection device detachably securing the customizable and replaceable panel to the customizable and replaceable mattress core and retaining the position of the two or more customizable and replaceable foam sections.
 9. The method as set forth in claim 8 wherein at least two of the three or more customizable and replaceable foam sections have a different foam comfort level.
 10. The method as set forth in claim 8 wherein the three or more customizable and replaceable foam sections are positioned in an asymmetric zone configuration, at least two of the foam sections have a different shape, and at least two of the foam sections have a different foam comfort level.
 11. The method as set forth in claim 8 wherein each of the three or more customizable and replaceable foam sections comprises a foam memory mattress core, an open coil mattress core, or a pocket coil.
 12. The method as set forth in claim 8 wherein at least two of the three or more customizable and replaceable mattress sections are different types of mattress cores.
 13. The method as set forth in claim 8 wherein the customizable and replaceable panel comprises a padded fabric panel.
 14. The method as set forth in claim 8 wherein the connection device comprises at least one zipper connector. 